NHTSA ID Number: 10153357
Manufacturer Communication Number: IS-19909
TSB/Document Date: 2019-02-19
Summary
This instruction sheet explains how to perform alternator conversion, from Bosch
to Delco Remy, on X3 vehicles
Instruction Sheet
IS-19909
BOSCH TO DELCO REMY ALTERNATOR INSTALLATION, X3-45
From E-5459 up to H-6179
MATERIAL
Order Main Kit IS19909, which contains
Part No.
Description
Qty
0610086
Alternator Mechanical Kit, Right
1
0610091
Adaptation Kit, Right, X3-45
1
IS-19908
Instruction Sheet
1
FI-19908
Feuille d’instructions
1
0610086 Alternator Mechanical Kit, Right
Part No.
Description
n
Ja
,
31
19
20
Qty
560720
Alternator Remy 55SI 24V-250A Pad
onMount
069892
ary
Pulley 8PK, 83 DOB in
m
eli
r
P
069894
Bracket, Alternator Remy
1
506065
Belt Poly V 8PK1435 EPDM QT+Aramide
2
5001308
SCR CAP HEXF N500 M10-1.5X40 G10.9
4
5002091
SCR CAP HEXF N500 M10-1.5X120 G10.9
4
5001137
WSH FL SS .203X.438X.06 (M5,#10)
2
5001180
NUT HEX NYRT SS 10-24
2
500411
WSH FL SS .260X.697X.05 (M6,1/4)
1
5001341
WSH FL SS 8.4X17X1.6 (M8,5/16)
1
500685
NUT HEX NYRT 5/16-18 SS
1
Writer: fl
v
i
ers
1
1
IS-19909
Page 2 / 23
0610091 Adaptation Kit, Right, X345
Part No.
Description
Qty
1
450580
BRACE, AC COMPRESSOR
5000360
STUD, M10-1.5X52 N500
1
N55439-02
RING TERMINAL 5MM / 16-14 / INSULATED
N33509-06
Shrink tubing
2
12”
0610030
Power cable RH alternator X345
1
0610034
Ground cable RH alternator
1
9
,
1
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20
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Writer:
IS-19909
Page 3 / 23
TOOLS
060088 CLUTCH EXTRACTOR
METRIC OPEN END WRENCH
SET
RATCHET AND SOCKET SET
– METRIC
HEX BIT
METRIC
SOFT FACED HAMMER
1 /8 OPEN END WRENCH
½ SQUARE DRIVE BREAKER
BAR
VOLTMETER / MULTIMETER
15/16”
THIN
CROWFOOT
WALL
ADAPTER.
SET
–
5
BELT TENSION GAUGE
,
1
n3
v
ary
n
sio
19
0
CUTTING
PLIERS
2
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Writer:
IS-19909
Page 4 / 23
PROCEDURE
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position. Apply vehicle lockout
procedures according to local policies.
Table of contents
OVERVIEW ............................................................................................................................................................. 4
ELECTRICAL SCHEMATICS ....................................................................................................................................... 5
BOSCH ALTERNATORS REMOVAL, RIGHT HAND SIDE ............................................................................................. 6
RIGHT HAND ALTERNATOR INSTALLATION .......................................................................................................... 11
RIGHT HAND ALTERNATOR INSTALLATION (CONTINUED) .................................................................................... 13
RIGHT HAND ALTERNATOR CONNECTIONS .......................................................................................................... 17
FUNCTIONAL TESTING.......................................................................................................................................... 20
19
APPENDIX A – LTD WIRE GUIDELINES ..................................................................................................................
21
20
1,
3
LABOR REFERENCE TABLE ....................................................................................................................................
23
an
J
ion
ers
v
OVERVIEW
ary
in
m existing Bosch alternators, their corresponding brackets and
The procedure involves removing lithe
e
r
harnesses and replacing them with
P a DelcoRemy 55SI alternator.
The alternators require new brackets and harnesses.
First time users should read the procedure before starting work on a vehicle. Best viewed in color.
Writer:
IS-19909
Page 5 / 23
ELECTRICAL SCHEMATICS
FIGURE 1: ALTERNATOR CONNECTIONS W/ HARNESS NUMBERS
9
,
1
n3
1
20
FIGURE 2: POWER CABLE CONNECTIONS IN MAIN POWER COMPARTMENT
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IS-19909
Page 6 / 23
BOSCH ALTERNATORS REMOVAL, RIGHT HAND SIDE
1.
Loosen bolt A on A/C belt tensioner.
2.
Unscrew and remove nut B.
3.
Remove the mechanical tensioner assembly.
4.
Remove the A/C compressor drive belts (2
side-by-side belts).
Note: Keep hardware for reuse
FIGURE 3
5.
Remove the LANG electromagnetic clutch
assembly.
9
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1
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FIGURE 4
6.
Hold the rotor with the 1 5/8 wrench.
Loosen and remove the M12 rotor
mounting screw.
REMOVING
SCREW
THE
M12
FIGURE 5
Writer:
IS-19909
Page 7 / 23
For the next step, use rotor extractor tool
#680888.
7.
Screw the extractor tool into the
straining washer only until the rotor pops
off the tapered shaft. Then work the
rotor off the shaft by hand with help from
soft faced mallet as needed.
TAKE OFF THE ROTOR
PULL OFF THE ROTOR WITH
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TSB/Document ID: IS-19909
Replacement Service Bulletin Number:
MFR Communication Date: 2019-01-31
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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